Structural column and process for making the same

ABSTRACT

The present invention relates to a column comprising a first elongate channel and a second elongate channel. In one aspect, the first elongate channel has a web and a pair of longitudinal flanges extending therefrom the front face of the web. The pair of flanges and the web define a trough. In one aspect, the second elongate channel also has a web and a pair of longitudinal flanges extending therefrom the front face of the web. In one aspect of the invention, the second elongate channel is affixed to the first elongate channel such that the front face of the web of the first elongate channel substantially faces the front face of the web of the second elongate channel, forming the column.

FIELD OF THE INVENTION

The present invention pertains to structural column and a process for making the same. In particular, it pertains to a process for making a column used in a racking system and a process for making a column.

BACKGROUND OF THE INVENTION

In the material handling industry, it is necessary to pre-build racking systems for warehouses that are capable of holding pallets of materials. The racking systems generally comprise posts, reinforcement supports, and shelves.

The columns of most conventional pallet racks are made from to two elongate substantially c-shaped channels. The channels conventionally comprise a web and two opposed flanges, as illustrated in FIGS. 1 and 2. In order to make a column, the respective flanges of the channels are welded together while the columns are facing each other, resulting in a post defining a cavity between the webs of the channels. One of the problems with this type of construction is that, when the distal ends of the flanges meet, the seam formed between each pair of respective flanges does not provide ample surface area with which to weld. Additionally, the bead of weld produced by welding the flanges often protrudes outwardly past the exterior sides of the flange. This protruding bead of weld may cause clearance problems when attempting attach the shelf support members.

Conventionally, the channels used to make the columns are hot-formed channels that comprise structural steel. The manufacturing process is not precise and often results in channels that have dimensional imperfections. These imperfections may be exacerbated when the channels are used to make columns. Conventional shelf support members are configured to attach to the column via clips which envelop three sides of the column. In order to ensure a good fit between the clip and the column, the web to web distance in the column, that is the distance between the webs of the two channels comprising the column, should be consistent. Because of the imperfections inherent in the channels, this consistency is difficult to achieve.

SUMMARY

In one embodiment of the invention, the present invention relates to a column comprising a first elongate channel and a second elongate channel. In one aspect, the first elongate channel has a web and a pair of longitudinal flanges extending therefrom the front face of the web. The pair of flanges and the web define a trough. In one aspect, the second elongate channel also has a web and a pair of longitudinal flanges extending therefrom the front face of the web. In one aspect of the invention, the second elongate channel is affixed to the first elongate channel such that the front face of the web of the first elongate channel substantially faces the front face of the web of the second elongate channel, forming the column.

DETAILED DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the instant invention and together with the description, serve to explain, without limitation, the principles of the invention. Like reference characters used therein indicate like parts throughout the several drawings.

FIG. 1 is a side elevational view of a prior art elongate channel showing one flange longer than the other.

FIG. 2 is a side elevational view of a prior art elongate channel showing flanges that have skewed side edges.

FIG. 3 is a side elevational view of a prior art column.

FIG. 4 is a side elevational view of one embodiment of a column according to the present invention.

FIG. 5 is a side elevational view of one embodiment of a column of the present invention, showing a first channel welded to a second channel.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be understood more readily by reference to the following detailed description of the invention and the Examples included therein and to the Figures and their previous and following description.

Before the present systems, articles, devices, and/or methods are disclosed and described, it is to be understood that this invention is not limited to specific systems, specific devices, or to particular methodology, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a strap” includes two or more such straps, and the like.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

In one embodiment of the present invention, the present invention relates to a column 10 comprising a first elongate channel 100 and a second elongate channel 200. In one aspect, the first elongate channel 100 has a web 110 and a pair of longitudinal flanges 120 extending therefrom the front face 130 of the web 110. The pair of longitudinal flanges 120 and the web 110 define a trough 140. In one aspect, the second elongate channel 200 also has a web 210 and a pair of longitudinal flanges 220 extending therefrom the front face 230 of the web 210. I a further aspect, a trough 240 is defined by the pair of longitudinal flanges 220 and the web 210.

In one aspect of the invention, the second elongate channel is affixed to the first elongate channel such that the front face 130 of the web of the first elongate channel substantially faces the front face 230 of the web of the second elongate channel, forming the column 10. In another aspect, the back surface 112 of the web 110 of the first elongate channel is spaced a predetermined distance from the back surface of the web 210 of the second elongate channel. The consistent web to web distance W_(d) between the respective back faces enables a consistent fit when attaching shelving support structures to the column 10. In yet another aspect, at least one of the distal ends of the longitudinal flanges 220 on the second elongate channel 200 are positioned substantially within the trough 140. By positioning the flanges of the second elongate channel within the trough of the first elongate channel 100, the web to web distance W_(d) may be regulated and normalized prior to welding the flanges of the two channels together.

In another aspect of the invention, as shown in FIG. 5, the longitudinal flanges on the second elongate channel may be substantially deformable, enabling them to be force fit into a portion of the trough 140 of the first elongate channel. This further enables the normalization of the web to web distance of the column. In one aspect, the second elongate channel is manufactured by cold-forming an elongate plate of structural steel. As one skilled in the art will appreciate, cold formed structural steel is more malleable than hot formed structural steel, which is beneficial when trying to force fit the second elongate channel 200 within the trough 140 of the first elongate channel 100.

In yet another aspect, the first elongate channel is affixed to the second elongate channel by welding a portion of each respective longitudinal flange 120 of the first elongate channel to a portion of the respective adjacent flange of the second elongate channel. In doing so, at least one bead of weld 400 is formed on the joint between the respective flanges of the first and second elongate channels. In one aspect, each bead of weld 400 extends outwardly away from a portion of the flange of the second elongate channel 200 and does not extend past a plane P_(f) defined by the distal end and a proximal end of the flange of the first elongate channel 100. Keeping the bead of weld inside that plane P_(f) eliminates a potential obstruction when attaching shelving support structures to the column.

Another aspect of the invention is a process for making a column 10 for a rack. The process comprises providing a first elongate channel as discussed herein above, providing a second elongate channel as discussed herein above, and affixing the second elongate channel to the first elongate channel such that the front face of the web 110 of the first elongate channel substantially faces the front face of the web 210 of the second elongate channel. In one aspect, the web of the first elongate channel 100 is spaced a predetermined distance from the web of the second elongate channel 200. In another aspect, as mentioned above, the distal ends of the longitudinal flanges 220 on the second elongate channel are positioned substantially within the trough 140.

Although several aspects of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention. 

1. A process for making a column for a rack comprising: providing a first elongate channel comprising a web and a pair of longitudinal flanges extending therefrom a front face of the web, wherein each longitudinal flange has a distal end, and wherein the flanges and web define a trough; providing a second elongate channel comprising a web and a pair of longitudinal flanges extending therefrom a front face of the web, wherein each longitudinal flange has a distal end; and affixing the second elongate channel to the first elongate channel such that the front face of the web of the first elongate channel substantially faces the front face of the web of the second elongate channel, wherein the web of the first elongate channel is spaced a predetermined distance from the web of the second elongate channel, and wherein the pair of longitudinal flanges on the second elongate channel is substantially deformable.
 2. The process of claim 1, wherein at least one of the distal ends of the longitudinal flanges on the second elongate channel is positioned substantially within the trough.
 3. The process of claim 1, wherein the distal ends of the longitudinal flanges on the second elongate channel are positioned substantially within the trough.
 4. The process of claim 1, wherein the second elongate channel is manufactured by cold-forming an elongate plate of structural steel.
 5. The process of claim 1, wherein the step of affixing the second elongate channel to the first elongate channel comprises welding a portion of each respective flange of the first elongate channel to a portion of the respective adjacent flange of the second elongate channel.
 6. The process of claim 5, wherein the welding step produces at least one bead of weld on a joint between respective flanges of the first and second elongate channels, and wherein each bead of weld extends outwardly away from a portion of the flange of the second elongate channel and does not extend past a plane defined by the distal end and a proximal end of the flange of the first elongate channel.
 7. A column manufactured by the process of claim
 1. 8. A column comprising: a first elongate channel comprising a web and a pair of longitudinal flanges extending therefrom a front face of the web, wherein each longitudinal flange has a distal end, and wherein the flanges and web define a trough; a second elongate channel comprising a web and a pair of longitudinal flanges extending therefrom a front face of the web, wherein each longitudinal flange has a distal end, wherein the second elongate channel is affixed to the first elongate channel such that the front face of the web of the first elongate channel substantially faces the front face of the web of the second elongate channel, wherein the web of the first elongate channel is spaced a predetermined distance from the web of the second elongate channel, and wherein the distal ends of the longitudinal flanges on the second elongate channel are positioned substantially within the trough.
 9. The column of claim 8, wherein the pair of longitudinal flanges on the second elongate channel is substantially deformable, enabling them to be force fit into a portion of the trough.
 10. The column of claim 8, wherein the second elongate channel is manufactured by cold-forming an elongate plate of structural steel.
 11. The column of claim 8, wherein the first elongate channel is affixed to the second elongate channel by welding a portion of each respective flange of the first elongate channel to a portion of the respective adjacent flange of the second elongate channel.
 12. The column of claim 11, further comprising a bead of weld on a joint between respective flanges of the first and second elongate channels, and wherein each bead of weld extends outwardly away from a portion of the flange of the second elongate channel and does not extend past a plane defined by the distal end and a proximal end of the flange of the first elongate channel. 